Outer cover having reinforcing fibers for an instrument panel airbag door

Abstract

An outer cover for an airbag door of an instrument panel includes a substrate formed from a polymer. A score line is formed into a first surface of the substrate to define an airbag deployment tear seam. A fiber is embedded into and integrally formed with the substrate. The fiber is disposed adjacent to the score line to limit particle separation of the polymer outer cover during deployment of an airbag through the outer cover.

1 . An outer cover for an airbag door of an instrument panel, the outer cover comprising:
 a substrate having a first surface and an opposing second surface;   a score line formed into the first surface of the substrate to define an airbag deployment tear seam, and   at least one fiber embedded into and at least partially encapsulated by the substrate, wherein the at least one fiber is disposed adjacent to the score line.   
     
     
         2 . An outer cover as set forth in  claim 1  wherein the at least one fiber is spaced an offset distance from the score line, with the offset distance between the range of 0 mm and 50 mm. 
     
     
         3 . An outer cover as set forth in  claim 1  wherein the score line partitions the first surface of the substrate into a first portion of the first surface and a second portion of the first surface, with the first portion and the second portion disposed across the score line from each other, and wherein the plurality of fibers includes a first fiber embedded into the first portion of the first surface, and a second fiber embedded into the second portion of the first surface and across the score line relative to the first fiber. 
     
     
         4 . An outer cover as set forth in  claim 1  wherein the substrate includes and is formed from a polymer. 
     
     
         5 . An outer cover as set forth in  claim 4  wherein the polymer forming the substrate includes one of polyvinyl chloride (PVC), thermoplastic olefin (TPO), or polyurethane (PU). 
     
     
         6 . An outer cover as set forth in  claim 1  wherein the at least one fiber includes and is formed from polyethylene terephthalate (PET), polyamide, cellulose, or glass. 
     
     
         7 . An outer cover as set forth in  claim 1  wherein the at least one fiber and the score line are not visible from the second surface of the substrate. 
     
     
         8 - 18 . (canceled) 
     
     
         19 . An airbag door for an instrument panel of a vehicle, the airbag door comprising:
 a core layer; and   an outer cover attached to the core layer, the outer cover including:
 a substrate formed from a polymer, and having a first surface and an opposing second surface; 
 a score line formed into the first surface of the substrate to define an airbag deployment tear seam having a generally U-shaped configuration; 
 wherein the score line partitions the first surface of the substrate into a first portion of the first surface and a second portion of the first surface, with the first portion and the second portion disposed across the score line from each other; and 
 a first fiber and a second fiber embedded into and at least partially encapsulated by the substrate, wherein the first fiber is embedded into the first portion of the first surface adjacent to the score line, and the second fiber is embedded into the second portion of the first surface adjacent to the score line. 
   
     
     
         20 . An airbag door as set forth in  claim 19  wherein the each of the first fiber and the second fiber are spaced an offset distance from the score line, with the offset distance between the range of 0 mm and 50 mm.